Apparatus for making rubberless tire bead assemblies

ABSTRACT

Rubberless tire bead assemblies are disclosed, containing either a single wire element or multiple wire elements wound about an axis to provide a plurality of convolutions of the single wire or multiple wire elements to provide the bead hoop and shape-retaining members engaging the bead hoop about the circumference of the bead hoop to retain the bead assembly in a planar configuration. Apparatus for forming the rubberless bead assemblies are disclosed which include bead formers and applicator devices for applying shape-retaining components to the formed bead assemblies.

RELATED APPLICATIONS

This application is a continuation of application Ser. No. 07/365,917,filed Jun. 14, 1989, which in turn is a continuation-in-part ofapplication Ser. No. 130,320 filed Dec. 8, 1987, both now abandoned.

BACKGROUND OF THE INVENTION

The present invention relates to rubberless tire bead assemblies and tonovel methods of manufacturing such tire bead assemblies to produce astrength efficiency tire bead assemblies which are of the sameefficiency as conventional wire tire bead assemblies which include arubber or polymeric coating thereon.

All automotive tire bead assemblies composed of round wire strengtheningelements in general use contain either a thin coating of rubber on thewire surface or contain wire elements embedded in a ribbon or elongateform of rubber, with the single exception being the rubberless cablebead. An important function of the rubber coating around the wireelement is to hold the multiple wire wraps together after forming sothat the tire bead assembly may be removed from the bead forming machineand handled during the course of the bead assemblies incorporation intothe tire during the tire building operation. The necessity for theexistence of such an adhesive function of the wire elements becomesincreasingly important for stiff, high-strength wires, such as steel,because of their spring-back characteristics. That is, although a wiremay be readily and neatly wound on a spool, the wire often becomesentangled upon removal from such a spool because of back tension, wiretwist and cast properties of the wire elements. Also, such beadassemblies tend to lose their constructional integrity upon removal fromthe bead forming drum unless the wire is rubber coated. The cable bead,generally composed of a wrap wire helically wound around a core hoopcontains an inherent compressive or resisting force and because of thehelical wrap geometry, cable beads require excessive forming times andoperations, thereby resulting in a substantially expensive beadassembly.

One deficiency of conventional rubber coated wire tire bead assembliesarises when under the low viscosity or near liquid environment thatoccurs during final curing of the completed tire, the adhesive nature ofthe rubber coated wires is substantially reduced and spring-back of thewire elements or other distortion to the original bead geometry mayoccur.

Furthermore, a limitation to bead geometry is inherent to conventionaltire bead assemblies comprised of multiple wraps of rubber ribboncontaining more than one wire. Such ribbons must be wound with theribbon width oriented exactly parallel to the winding axis so as toconsume in each wrap of ribbon precisely the same length on each side ofthe ribbon. This forming requirement prohibits constructions, such asthose containing conical geometric form such as would mate with a tirewheel rim having state-of-the-art tapered surfaces of revolution.

A further potential deficiency of state-of-the-art beads in general useis the inherent absence of void space free of rubber internal to thebead wire array.

Additionally, although in conventional round wire tire bead assembliesthe rubber bonding or coating thereon facilitates bonding the wirestogether to provide the resultant tire bead assembly or bundle, the useof a rubber coating on the bead wires to manufacture tire beadassemblies requires a separate rubber making operation and expensiveextrusion equipment to effectively produce the thin coating on the wireelements that comprise the tire bead assembly. The resultant reducedspeed limitations in manufacturing such tire bead assemblies and thenecessity of required overlaps of the wire endings for proper adherenceof wire end to bead assembly and the tendency of the wire endings tospring away from the bundle during the tire making processes areproblems that are inherent in such rubber-coated tire bead assemblies.Additionally, the high cost of the special formulated rubber coatingsresults in higher cost tire bead assemblies which, if eliminated, wouldsubstantially reduce the time required for manufacturing such tire beadassemblies and would decrease the cost of such manufacture processthereby providing higher speed and greater productivity during the beadmaking operations.

Prior art attempts to make a rubberless tire bead assemblies include,for example, Lejeune U.S. Pat. No. 3,949,800, Grosch, U.S. Pat. No.4,216,814, Pfeiffer U.S. Pat. No. 4,290,471, and Mertin, U.S. Pat. No.4,406,317 patents which disclose a plurality of rectangular-shaped wireelements to make a bead assembly having sharp corners. The resultantrubberless tire bead assemblies exhibit an absence of voids within thebead assemblies and require a special ductile steel material to bepositioned around the bead as an integral part of the bead making cycle.Such tire bead assemblies possess sharp corners that adversely effectother materials in the bead are during service, do not contain voidreservoirs within the bead assemblies, utilize expensive polygon-shapedwire elements, and require that the bead making cycle is dominated bythe time necessary to deform and position steel materials around thebead at numerous locations to retain the bead assembly. Accordingly,such beads have enjoyed little, if any, commercial acceptance.

Additionally a rubberless round wire bead with homogeneous joining oftouching or contiguous wires, incorporating joining mean such assintering has been disclosed by Pearce U.S. Pat. No. 3,372,894.

Additionally, the conventional cable bead assembly is a rubberless tirebead assembly which is generally comprised of at least two wirecomponents, a wire wound about a core wire, and a ferrule component forjoining the wound wire ends. However, such cable bead assemblies tend tobe excessively flexible and prone to bending and require excessive timecycles in manufacturing the bead assembly thereby resulting in increasedcosts of manufacture. See, for example, Gore U.S. Pat. No. 2,069,525 tosuch a cable bead assembly.

U.S. Pat. 4,039,015 discloses a rubberless bead which may be formed, forexample, as the result of interlocking a multiple number of independenthoops with welding or interlocking a multiple number of hoops twistedfrom a single wire length with welding. However, such constructions arereadily distorted due to the helical or nonparallel nature of individualwire axes one to another. Furthermore, the disclosed construction madefrom a single length of wire contains a relatively large number of wirecrossover points which represent points of nonuniform stressdistribution under load and potential wear and deformation cites.

SUMMARY OF THE INVENTION

It is one object of the present invention to provide novel and uniquerubberless tire bead assemblies possessing strength efficienciescorresponding to rubber-coated prior art tire bead assemblies.

It is another object of the present invention to provide novel means formanufacturing rubberless tire bead assemblies which eliminate the rubbercosts in manufacturing bead assemblies and results in higher speed andgreater productivity during the tire bead making operations.

It is a further object of the present invention to utilize a variety ofshape retaining means or bonding methods for holding a rubberless tirebead assembly together after manufacture of the bead assembly or bundleto provide a rubberless tire bead assembly possessing interstitial voidsbetween the wires wherein each of the convolutions of the wire elementsare substantially in a planar contact relationship with adjacentconvolutions of the wire elements and all wire axes are substantiallyparallel one-to-another.

A further object of the present invention is to provide a novelapparatus for manufacturing unique rubberless single wire tire beadassemblies wherein at least one end of the predetermined length of thesingle wire is positioned internal to the array of wires comprising thebody of the tire bead assembly.

It is another object of the present invention to provide a novelapparatus for manufacturing a rubberless single wire tire bead assemblywherein at least one end of the predetermined length of the single wireis positioned externally on the side wall surface of the tire beadassembly.

It is still another object of the present invention to provide a novelapparatus for manufacturing unique rubberless tire bead assemblycomprised of a plurality of predetermined lengths of substantially roundwires in a layered sequence wherein at least one end of thepredetermined lengths of wires is positioned on either the insidediameter surface of the tire bead assembly or is positioned on the sidewall surface of the tire bead assembly.

It is yet another object of the present invention to provide a novelapparatus for manufacturing rubberless tire bead assemblies comprised ofa plurality of predetermined lengths of substantially round wireswherein the inside diameter surface of the bead assembly is tapered.

The strength efficiency of single wire tire bead assemblies comprised ofdensely packed symmetrical bead construction, such as, for example,2-3-2, 4-5-6-5, 4×4, and 3-4-5-4, having the elongated wire elements, ofnominally circular cross section and free of rubber or other polymericmaterial, has resulted in single wire tire bead assemblies which possessa strength sufficiency equivalent to conventional round wire beadshaving a rubber bonding or coating on the wires. The strength efficiencyof rubberless tire bead assemblies comprised of a plurality ofpredetermined lengths of substantially round wires of symmetrical beadconstructions, such as, 3×3, 4×4, and 5×5 and others, are equivalent toconventional ribbon-type bead assemblies. The practical advantage ofeliminating rubber from the tire bead assembly or bundle includes theelimination of the bead rubber coating costs and improved manufacturingoperation, such as, higher processing cycle speeds and increasedproductivity in the bead making operation. The resultant rubberless beadassemblies include a void volume or region within the tire bead assemblyor bundle within the wire array, which provides a reservoir orcollection region for the air entrapped during the positioning of thetire bead assembly or bundle within the tire carcass during the tirebuilding operation. Additionally, the method of manufacture permits theopportunity to weld or otherwise bond either the wires and wire ends atcritical points in or on the bead bundle so as to prevent distortion ofthe wire and movement away from the bead or bundle during the tiremanufacturing operation.

The variety of shape-retaining means for bonding or for engaging atleast a portion of the plurality of the convolutions of the single wireor filament superimposed upon each other periodically about the beadcircumference to hold the bead assembly or bundle together, include theuse of metal clip members applied preferably simultaneously at severallocations about the bead circumference, as well as other bonding devicesand methods such as, using metal ties, spring clips, spiral wrappedfabrics or wires around the entire or a portion of the beadcircumference, spot soldering, brazing or welding periodic locationsabout the bead circumference, use of solder-coated wire in the beadwires, gluing or use of adhesives, applying fusible polymeric materialperiodically or entirely around the bead circumference, dipping the beadassemblies into an adhesive coating, and miniature hose clamp memberswhich securely engage at least a portion of the convolutions of thesingle wire to hold the bead assembly. It should be understood that eventhough most of the above described methods are applicable to the beadassembly after the component wire wraps have been formed, themethodology envisioned includes application of bonding means or materialto the wire feeding into the forming apparatus, i.e., periodic orcontinuous application of bonding means or material to the wire beforeor during formation of the bead assembly. Each method or techniqueretains and holds the wires within the bead assembly in surface contactwith one another substantially in a plane parallel to the remainingconvolutions of the wire within the tire bead assembly and provides thatvoid volumes exist between the convolutions of the wire within the tirebead array.

In conventional bead making processes, the wire strand or strengtheningelement is coated with a specially formulated rubber coating which, whenthe single wire or ribbon of wires is wound upon itself to form the tirebead assembly, holds and retains the resultant bead assembly togetherfor subsequent handling and usage. In subsequent positioning of suchrubber coated tire bead assemblies within the tire during the tirebuilding operation, the rubber coating is vulcanized to provide a curedtire bead assembly within the tire which does not include voidsextending along the circumferential length of the bead assembly. Duringsuch known tire building operations, the folding of the tire carcasssidewall materials about the bead ring assembly entrap air and result inthe occurrence of air bubbles. By utilizing the unique rubberless tirebead assembly in accordance with the present invention, the void volumesthat extend substantially throughout the circumferential length of thetire bead hoop, permits the air bubbles to be dissipated and minimized,thereby providing an improved finished tire. Moreover, the tire beadassembly geometry and structure resists changes when the bead assemblyis positioned within the tire and undergoes vulcanization. That is tosay, the geometry of a conventional prior art tire bead assembly maybecome distorted out of a planar configuration during vulcanization ofthe tire thereby resulting in a geometrical distorted tire bead or lossof precise bead position when it is cured within the tire carcass. Suchproblems of the prior art rubber coated wire bead assemblies arealleviated by the present invention.

Additionally, in accordance with the present invention, any residualforces tending to distort the geometry of the formed bead aresubstantially minimized and eliminated. In contrast, the formation ofthe bead assembly resulting from the interlocking of a multiple numberof hoops from a single wire length in accordance with prior art U.S.Pat. No. 4,039,015, may result in highly localized residual forces dueto the inherent friction of the numerous crossover points in thesubstantially nonparallel relation of the wires.

When the completed rubberless tire bead assemblies in accordance withthe present invention have been constructed, it may be desirable to usepreformed clips which may relatively quickly engage at least a portionof the convolutions of the wire while the tire bead assembly is on theforming drum. Furthermore, if such clips are used as a precursor meansprimarily to facilitate removal of the formed bead from the formingdrum, subsequent operations may well be utilized to complete tire beadassembly, such as, spot welding, soldering, gluing, spot dipping thebead assembly into an adhesive or the use of a fabric or wire wraparound the circumference of the bead assembly, to provide that theelongated wire elements of a nominally circular cross section arepositioned parallel relative to one another from convolution toconvolution with the elongated element surfaces in direct contact withone another such that the void volumes may exist between theconvolutions of the elongated wire elements of the tire bead assembly.

It is envisioned that the principle of precursor, or partial, bonding onthe forming drum may take a variety of forms including those mentionedabove for completing the tire bead assembly.

In still a further embodiment of the present invention, a method ofmanufacturing densely packed rubberless single wire tire bead assemblieswherein the wire ends are positioned internal to the body of the tirebead assembly or in an internal position of the wire array or wherein atleast one of the termination ends is positioned external to the tirebead assembly, either on the inside diameter surface or on the sidewallsurface. When at least one tire bead end of the elongated wire orstrength element is positioned on the inside diameter surface of thetire bead assembly, termination ends of the elongated wire material maybe treated in accordance with my co-pending application Ser. No.085,642, filed Aug. 13, 1987, now U.S. Pat. No. 4,820,563, issued Apr.11, 1989, and the disclosure and the treatment of bead ends therein isincorporated herein by reference to improve the strength efficiency ofthe resultant rubberless tire bead assemblies.

The present invention consists of certain in novel features andstructural details hereinafter fully described, illustrated in theaccompany drawings, and particularly pointed out in the appended claims,it being understood that various changes in the details may be madewithout departing from the spirit and scope thereof or sacrificing anyadvantages of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary axial plan view of a 5×5 rubberless multiplewire tire bead assembly in accordance with the present invention;

FIG. 2 is a cross-sectional view of the 5×5 rubberless multiple wiretire bead assembly taken along lines 2--2 of FIG. 1;

FIG. 3 is a fragmentary axial plan view of a 5×5 rubberless single wiretire bead construction in accordance with the present invention;

FIG. 4 is a cross-sectional view of a 5×5 rubberless single wire tirebead assembly taken along lines 4--4 of FIG. 3;

FIG. 5 is a side elevational view of a rubberless tire bead assembly inaccordance with the present invention showing shape retaining means forengaging at least a portion of the convolutions of the wires within thebead assembly spaced equally about the bead circumference to retain thetire bead assembly in a planar configuration;

FIG. 6 is an enlarged cross-sectional view taken along lines 6--6 ofFIG. 5 showing a dense packed 3-4-5-4-3 rubberless tire beadconstruction having one embodiment of the shape-retaining means engagingat least a portion of the plurality of the convolutions of the singlewires to retain the tire bead assembly in a planar configuration inaccordance with the present invention;

FIG. 7 is an enlarged cross-sectional view of dense packed 4-5-6-5rubberless single wire tire bead assembly showing a further embodimentof the shape-retaining means engaging the tire bead array in accordancewith the present invention positioned about the tire bead assembly toretain the surfaces of the wires in contact with each other such thatvoid volumes exist between the convolutions of the wire elements withinthe bead assembly;

FIG. 8 is an enlarged cross-sectional view of dense packed 3-4-5-4-3rubberless tire bead assembly showing another embodiment of theshape-retaining means engaging the tire bead array in accordance withthe present invention positioned about the tire bead assembly to retainthe elongated wire element surfaces in contact with each other such thatvoid volumes exist between the convolutions of the wire elements withinthe bead assembly;

FIG. 9 is an enlarged cross sectional view of a dense packed 4-5-4 tirebead assembly showing another embodiment of the shape-retaining meansengaging the tire bead array in accordance with the present inventionpositioned and engaging at least a portion of the plurality ofconvolutions of the single wire in direct contact with each other suchthat void volumes exist between the wire elements within the beadassembly;

FIG. 10 is a fragmentary elevational view of a rubberless tire beadassembly showing another embodiment of the shape retaining meansengaging the tire bead array in accordance with the present inventionperiodically and circumferentially engaging the tire bead assembly toretain the elongated wire element surfaces in direct contact with eachother such that void volumes exist between the wire elements;

FIG. 11 is an enlarged cross-sectional view of a 4×4 rubberless tirebead assembly showing another embodiment of the shape-retaining means inaccordance with the present invention periodically wrapped around thetire bead assembly to retain the elongated wire element surfaces incontact with each other such that void volumes exist between the wireelements within the bead assembly;

FIG. 12 is an enlarged cross-sectional view of a dense packed 4×4rubberless tire bead assembly showing another embodiment of theshape-retaining means for engaging in accordance with the presentinvention engaging the tire bead assembly to retain the elongated wireelements surfaces in contact with each other such that void volumesexist between the wire elements;

FIG. 13 is an enlarged plan view of one end of the shape-retaining meansmembers as shown in FIG. 12;

FIG. 14 is a fragmentary axial plan view of a 4×4 rubberless tire beadassembly showing the shape-retaining means in accordance with thepresent invention periodically engaging the tire bead assembly to retainthe elongated element surfaces in direct contact with each other suchthat void volumes exist between the wire elements within the tire beadarray;

FIG. 15 is a cross-sectional view of the 4×4 rubberless tire beadassembly taken along lines 15--15 of FIG. 14;

FIG. 16 is a cross-sectional view of a 2-3-2 rubberless single wire tirebead assembly wherein the elongated single wire has an adhesive orsolder coating applied to the wire surface either before or during thebead assembly process in accordance with the present invention;

FIG. 17 is a cross-sectional view of the 2-3-2 rubberless tire beadassembly of FIG. 16 showing the subsequent bonding treatment inaccordance with the present invention of the adhesive or solder coatingto retain the elongated wire element surfaces in contact with other wiresurfaces such that void volumes exist between the wire elements withinthe tire bead assembly;

FIG. 18 is a fragmentary axial plan view of a 4×4 rubberless single wiretire bead assembly in accordance with the present invention whereinperiodic adjacent wraps or convolutions of the wire element are weldedor bonded together during the manufacture of the assembly to retain theelongated wire elements in contact with each other such that voidvolumes exist between the wire elements;

FIG. 19 is a cross-sectional view of the 4×4 rubberless single wire tirebead assembly taken along lines 19--19 of FIG. 18;

FIG. 20 is a fragmentary axial plan view of a 4×4 conventional prior artrubber coated single wire tire bead assembly illustrating the overlapcondition of the inner and outer termination ends to provide aconventional tire bead assembly;

FIG. 21 is a fragmentary axial plan view of a 4×4 rubberless wire tirebead assembly showing the wire termination ends of the wire member beingknurled to increase the surface area thereof to reduce the overlap fromthe inner and outer termination ends to provide a strength efficienttire bead assembly in accordance with the present invention;

FIG. 22 is a fragmentary axial plan view of a 4×4 rubberless tire beadassembly wherein the inner termination end positioned on the innerdiameter of the tire bead assembly is mechanically ground to provide atapered wire termination end in accordance with the present invention;

FIG. 23 is a side plan view of a rubberless tire bead assembly showingmeans for engaging, such as, a close spiral fabric wrapping and a spacedspiral fabric wrapping which retains the tire bead assembly in a planarconfiguration and the wire elements in contact with each other inaccordance with the present invention;

FIG. 24 is a fragmentary axial plan view of a rubberless tire beadassembly showing the inner termination end or ends on the insidediameter surface of the tire bead assembly being rounded in accordancewith the present invention;

FIG. 25 is a fragmentary axial plan view of a rubberless tire beadassembly showing a cushion positioned between the inner termination endor ends and the inside diameter surface of the tire bead assembly inaccordance with the present invention;

FIG. 26 is a fragmentary axial plan view of a rubberless tire beadassembly showing the softening or heat treatment of the innertermination end or ends, and the inside diameter surface of the tirebead assembly in accordance with the present invention;

FIG. 27 is an axial plan view of a rubberless tire bead assembly showinga wedge means positioned at the termination end or ends and the insidediameter surface of the tire bead assembly in accordance with thepresent invention;

FIG. 28 is a fragmentary axial plan view of a 3×3 tire bead assemblyshowing a high strength elongated wrap material having a portionanchored internal to the bead assembly and a portion external andwrapped around the bead assembly to retain the wire surfaces insubstantial contact with each other such that void volumes exist betweenthe wire elements in accordance with the present invention;

FIG. 29 is an enlarged cross-sectional view taken along lines 29--29 ofFIG. 28;

FIGS. 30a-30d are schematic sequential drawings illustrating the methodof forming a 2-3-2 rubberless single wire tire bead assembly with theinside diameter surface of the bead assembly free of a wire terminationend in accordance with the present invention;

FIGS. 31a-31f are schematic sequential drawings illustrating the methodof forming a 2-3-2 rubberless tire bead assembly from a single wire withthe inside diameter surface of the tire bead assembly free of a wiretermination end and wherein one of the wire termination ends ispositioned internal within the bead assembly in accordance with thepresent invention;

FIGS. 32a-32f are schematic sequential drawings illustrating the methodof forming a 2-3-2 rubberless tire bead assembly from a single wirewherein both wire termination ends are positioned internal within thetire bead assembly in accordance with the present invention;

FIGS. 33a-33c are schematic sequential drawings illustrating the methodof forming a six wire non-compact rubberless tire bead assembly formedfrom a single wire having the wire termination ends positioned internalor along the sidewall of the tire bead assembly and held in symmetricalorientation by the periodic positioning of clip members about thecircumference of the bead assembly in accordance with the presentinvention;

FIGS. 34a-34e are schematic sequential drawings illustrating the methodof forming a 4×4 rubberless tire bead assembly containing multiple wireswherein the bead assembly has a tapered bead base and a means forengaging in the circumference of the tire bead assembly to retain the4×4 rubberless tire bead assembly in a dense compact condition inaccordance with a further embodiment of the present invention;

FIGS. 35a-35c are schematic sequential drawings illustrating one methodof forming a 4×4 rubberless tire bead assembly containing four wireelements wrapped radially therearound with the termination ends beingpositioned in the inside and outside diameter surfaces of the tire beadassembly in accordance with the present invention;

FIGS. 36a-36c are schematic sequential drawings illustrating anothermethod of forming a 4×4 multiple wire tire bead assembly wherein thetermination ends are positioned on the sidewall of the bead assembly inaccordance with the present invention;

FIG. 37 is an axial plan view of the 4×4 multiple wire tire beadassembly of FIGS. 36a-36c showing the termination ends on the sidewallof the bead assembly;

FIG. 38 is a simplified representation of apparatus provided inaccordance with the present invention for forming a rubberless beadassembly;

FIG. 39 illustrates a formed tire bead assembly including a plurality ofshape retaining elements;

FIG. 40 is a simplified representation of tire bead assembly formingapparatus provided in accordance with the present invention whichincludes a plurality of forming members carried by a moving assembly formovement between a plurality of positions during forming of tire beadassemblies; and,

FIG. 41 is a simplified representation of a further embodiment forapparatus for forming a rubberless tire bead assembly which includes amoving apparatus having a plurality of gripping elements for engaging aformed tire bead assembly during removal of the tire bead assembly fromthe bead forming apparatus.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purpose of facilitating an understanding of the scope of thepresent invention, illustrated in the drawings of several embodiments ofthe present invention, like numerals have been used throughout theseveral views to designate the same or similar parts. The presentinvention is directed to rubberless tire bead assemblies and to novelmechanical and physical treatments of the assembled tire bead assemblyto hold and retain the tire bead assembly within a planar configuration.Additionally, the present invention is directed to novel apparatus formanufacturing rubberless tire bead assemblies containing either a singleelongated wire or strengthening element or containing multiple or aplurality of elongated wire or strengthening elements. And, as used inthe present disclosure, the reinforcing or strengthening elementutilized in manufacturing the ribbon-type tire bead assembly as well asthe single reinforcing element tire bead assembly is a wire element.

FIG. 1 illustrates and discloses a 5×5 tire bead assembly 12 that ismanufactured by utilizing five strands of a wire or strengtheningelement 14, radially wrapped upon themselves five times to provide the5×5 rubberless tire bead assembly 12. Each of the wires 14a-14e have aninner termination end 15, as shown in FIGS. 1 and 2, on the innerdiameter surface 16 of the bead assembly 12, and an outer terminationend 17, as shown in FIG. 1, on the outer diameter or peripheral surface18 of the bead assembly 12. The tire bead assembly 12 of this particular5×5 construction comprised of multiple convolutions of five elongatedwire elements 14a-14e, each being nominally circular in cross-sectionand each being free or substantially free of any elastomer or rubberenvelope about the wire elements 14a-14e. The elongated wire elements14a-14e axis of each wire 14a-14 e are positioned substantially parallelrelative to one another and parallel from convolution to convolutionwith the wire surfaces 21 in contact with at least adjacent convolutionsof the wires such that void volumes exist between the wire elements 14,as shown in FIG. 2.

FIGS. 3 and 4 illustrated a 5×5 single wire tire bead assembly 12comprised of a single wire element 14 wound upon itself twenty-fivetimes. As shown in FIG. 3, the inner termination end 15 of the singlewire element 14 is on the inner diameter surface 16 of the tire beadassembly 12. As is shown in FIG. 4, the elongated wire element 14 ispreferably circular in cross-section and is free or substantially freeof an envelope of elastomer, polymeric or rubber material, with each ofthe element axis being parallel relative to one another from convolutionto convolution and with the elongated wire element surfaces 21 in directcontact with each other such that void volumes 19 exist between theelements, as shown in FIG. 4. The phrase free or substantially free ofan envelope of elastomeric or rubber-like materials means that the wireelements used in accordance with the invention is substantially free ofany elastomeric or rubber-like materials prior to incorporation into thenovel tire bead assemblies. That is, the wire elements are substantiallyfree of elastomeric or rubber-like materials that prevent the wireelements from coming into contact with each other from convolution toconvolution or within a convolution. The present invention does notexclude the use of material coatings that facilitate lubrication, wearresistance, corrosion resistance or adhesion to other components of thebead area in the finished tire.

FIG. 5 illustrates a completed 3-4-5-4-3 dense packed rubberless singlewire tire bead assembly 12 that has been wound on a tire bead former(not shown). The present invention contemplates the utilization ofshape-retaining means 20 for engaging at least a portion of theplurality of the convolutions of the single wires 14 which comprise thetire bead assembly 12 of the bead array periodically about the beadcircumference to retain the tire bead assembly 12 in a planarconfiguration. As shown in FIG. 5, the shape-retaining means 20 forengaging the completed tire bead assembly 12 engage the bead bodies atapproximately six locations circumferentially and equally spaced aboutthe circumference of the tire bead assembly 12.

A variety of shape-retaining means 20 for engaging, bonding or otherwiseholding and retaining the rubberless bead assembly or bundle togetherafter manufacture of the tire bead assembly or bundle is contemplated bythe present invention. The shape-retaining means 20 for engaging,bonding, or retaining the wire elements within the tire bead arrayprovides a rubberless tire bead assembly 12 possessing interstitialvoids 19 between the wire elements 14 when the surfaces of theconvolutions of the wire elements are substantially in planar contactrelationship between adjacent convolutions of the wire elements. Thevariety of shape-retaining means 20 for engaging or bonding at least aportion of a plurality of the convolutions of the single wire 14 ormultiple wires within the tire bead assembly 12, include the use of apreformed metal clip member 22 about at least a portion of the pluralityof the convolutions of the wire element 14 of the 3-4-5-4-3 dense packedtire bead assembly 12, as shown in FIG. 6. FIG. 7 illustrates anotherembodiment of the shape-retaining means 20 which comprises a metal clipmember 22 wrapped around the 4-5-6-5 dense packed single wire tire beadassembly 12. FIG. 8 illustrates another embodiment of theshape-retaining means 20 which comprises a twisted filament or wire tieretaining member 24 which is wrapped around a dense packed 3-4-5-4-3rubberless tire bead assembly 12. FIG. 9 illustrates another embodimentof the shape-retaining means 20 which comprises a profiled retainingclip member 26 which is positioned periodically about the circumferenceof a dense packed 4-5-4 tire bead assembly 12 for engaging at least aportion of the plurality of convolutions of the single wire 14 of thetire bead assembly to retain the tire bead assembly 12 in a planeperpendicular to the bead axis of revolution, with the elongated wireelement surfaces in contact with each other such that void volumes 19exist between the elements. The use of preformed retaining clip members22 and 26 (FIGS. 6 and 9) substantially reduces the significant delaybetween successive bead forming cycles on the bead making machines (notshown). However, the scope of the present invention is not limited tothe use of preformed clip members but is directed generally towards theuse of shape-retaining means for engaging the convolutions of the wireelements, which comprise the formed bead assembly, to hold theconvolutions substantially parallel relative to one another and parallelfrom convolution to convolution with the elongated wire

FIG. 10 illustrates another embodiment of the shape-retaining means 20for engaging the tire bead assembly to retain the elongated wireelements 14 in direct contact with each other so that void volumes existbetween the wire elements. Specifically, FIG. 10 discloses a helicalretaining clip or spring wrap member 28 which circumferentially engagesthe completed tire bead assembly to retain the bead assembly in a planeperpendicular to the bead axis of revolution. FIG. 11 discloses anotherembodiment of the shape-retaining means 20 which includes a mechanicallyinterlocked retaining member 30 which is periodically wrapped around thetire bead assembly 12 to hold the elongated wire surfaces in contactwith each other such that void volumes 19 exist between the wireelements. As shown in FIG. 11, the tire bead assembly 12 is comprised offour elongated wires 14a, 14b, 14c, and 14d that are sequentiallywrapped around a forming mandrel (not shown) to form a 4×4 rubberlesstire bead assembly. In FIG. 12, the shape-retaining means 20 includes amechanical locking member 30 which is wrapped about the completed 4×4tire bead assembly to force the 4×4 tire bead assembly into a close ordense packed configuration. FIG. 13 is an enlarged view of one end 30aof the mechanically locking member 30 showing the engagement of end 30awithin an opening 30b of the member 30 which is positioned about thebead assembly 12 to form the dense packed 4×4 tire bead assembly.

FIGS. 14 and 15 illustrate a 4×4 rubberless tire bead assembly 12wherein the shape-retaining means includes chemically bonding 32 thebead assembly periodically about the circumference of the bead assemblyor hoop to retain the elongated wire elements in contact with each othersuch that void volumes exist between the elements. As shown in FIGS. 14and 15, the chemical bonding 32 may be the use of a solder, adhesive,braze weld, or polymeric encasement of the bead assembly 12 to retainthe wire elements 14 in contact with each other such that void volumes19 exist between the elements. The chemical bonding 32 may include theuse of a contact adhesive applied either during formation of the beadassembly or dipping operation wherein an adhesive or glue is appliedabout the outer surface of the tire bead assembly 12 after formation ofthe bead assembly. The utilization of a chemical bond 32 must besufficient to retain the formed and completed tire bead assembly 12 in aplane perpendicular to the bead axis of revolution for subsequentinsertion and use in the tire making process.

It is within the scope of the present invention that in certain cases itmay be desirable for economic or other reasons to employ secondaryoperations to the formed rubberless bead such as dipping in polymericmaterial or otherwise molding with a polymeric material such that theentire bead wire array is filled with materials. In such instances, thevoid regions or volumes will not exist within the bead assembly.

FIGS. 16 and 17 illustrate the manufacture of a 2-3-2 rubberless tirebead assembly 12 wherein the wire element 14 is coated 34 with a solderor adhesive material either prior to or during forming operation for thetire bead assembly 12. After formation of the tire bead assembly,subsequent heating the solder coating or further chemical curing of theadhesive coating 34 results in a rubberless tire bead assembly 12 havingthe bead array configuration, as substantially shown in FIG. 17. Thecompleted tire bead assembly 12 includes the cured chemical adhesive orsolder coating 34 retaining the elongated wire element 14 surfaces 21 insubstantial contact with at least an adjacent wire convolution such thatvoid volumes 19 exist between the wire elements 14 to retain the tirebead assembly in a plane perpendicular to the bead axis of revolutionfor subsequent use in the tire making process.

FIGS. 18 and 19 illustrate either a single wire 4×4 rubberless tire beadassembly or a multiple or four-wire 4×4 rubberless tire bead assemblywhich includes a further embodiment of the shape-retaining means. Duringthe formation or manufacture buildup of the tire bead assembly 12 on theforming drum (not shown), periodic contact welds or contact soldering 32chemically bonds adjacent convolutions of the wire element or elementstogether. FIG. 19, shows a cross-section view of the bead array andillustrates the periodic spot welding or soldering, which may be bothvertical and horizontal between convolutions of the wire element byelements to connect adjacent wire elements 14 to chemically bond andretain the elongated wire elements in contact with each other so thatvoid volumes 19 exist between the wire elements. This chemical bondingtreatment during the manufacture of rubberless tire bead assembliesprovides a rubberless tire bead assembly 12 which is retained in a planeperpendicular to the bead axis of revolution for subsequent use in thetire building process.

FIG. 20 illustrates a conventional prior art 3×3 tire bead assembly,wherein the individual wire elements 14 each include an envelope orrubber coating 23. In such bead assemblies, the overlapped lengthbetween the inner termination end 15 with respect to the outertermination end 17 is length A. The length A is necessary to increasethe adhesion surface area so as to provide equivalent pull out adhesiveforce in the overlapped region. Such extended overlapped lengths of thetermination ends of the wire elements 14 may provide an out-of-balancecondition for such prior art tire bead assemblies.

FIG. 21 illustrates a rubberless 3×3 tire bead construction wherein theinner termination end 15 and the outer termination end 15 includes aportion 36 adjacent the ends thereof which are knurled or otherwiseroughened. Such knurling or roughening results in a reduced overlappedlength B, as shown in FIG. 21, which thereby reduces the amount ofmaterial necessary to be utilized in constructing the rubberless tirebead assembly 12 and reduces the amount of out-of-balance. The knurling,roughening or threading of the wires, adjacent the ends thereof,provides an increased adhesion surface area so as to provide increasedresistance to the pullout force in the overlapped region B. Moreover, itis within the scope of the present invention to provide that the entirelength of wire element 14 utilized in constructing the rubberless tirebead assembly 12 in accordance with the present invention may beroughened or knurled to increase the adhesion surface area with respectto the wire bead assembly and the tire carcass material that surroundsthe bead when the bead is placed in the tire during the tire buildingoperation.

FIG. 22 illustrates the incorporation of my co-pending application Ser.No. 085,642, filed Aug. 13, 1987, now U.S. Pat. No. 4,820,563, whichdiscloses the specialized treatment of the bead wire ends when they arepositioned within a tire bead assembly. Specifically, FIG. 22illustrates a rubberless tire bead assembly having an inner terminationend 15 and an outer termination end 17, with the inner termination end15 positioned on the tire bead inner diameter surface 16. As shown inFIG. 22, a grinder or other mechanical means 37 is utilized to engagethe inner termination end 15 to grind the same to provide a taperedportion 15a thereon or to otherwise provide an angle cut on the tirebead end 15 to eliminate the sharp defined stress point or contact pointbetween the wire termination end 15 and the inner peripheral surface 16of the tire bead assembly.

FIG. 23 is an axial plan view of a rubberless tire bead assembly 12 inaccordance with two additional embodiments of the present invention.Specifically, FIG. 23 discloses and illustrates a close spiral fabricwrapping 38 which is wrapped continuously about the tire bead assembly12 or bead hoop to retain the convolutions of either the single wire orplurality of wires comprising the tire bead array in substantial contactwith one another to retain the bead assembly in a plane perpendicular tothe bead axis of revolution. As shown also in FIG. 23, a spiral-fabricwrapping 40 having gaps 42 therebetween is disclosed and continuouslywrapped about the circumference of the tire bead assembly 12 or beadhoop to retain the convolutions of either the single wire or pluralityof wires comprising the bead array in substantial contact with oneanother and to retain the bead assembly in a plane perpendicular to thebead axis of revolution. The continuous shape-retaining means, asdisclosed in FIGS. 16, 17, and 23, may well be applied in a subsequentapplication after the bead assembly has first been formed and boundusing precursor clip members, as shown in FIGS. 6-12. The embodiments ofthe present invention, as disclosed in FIG. 23, as well as theembodiments of the present invention shown in FIGS. 16 and 17, showcontinuous bonding methods that continually engage the wire elements 14throughout the bead assemblies' circumferential length thereof to retainthe tire bead assembly in a plane while at the same time maintaining thesubstantially round wire elements 14 in a parallel nonvariable crosssectional geometry with the elongated wire axis being parallel to oneanother and parallel from convolution to convolution. In such acondition, the elongated wire element 14 surfaces are in contact withadjacent convolutions such that void volumes exist between the wireelements. It is understood that a variety of wrapping materials such astapes, films, wires can be employed advantageously.

FIG. 24 illustrates a rubberless tire bead assembly 14 in accordancewith the present invention wherein the inner termination end 15 of thewire element or elements 14 is mechanically rounded at the point wherethe inner bead termination 15 engages the inner peripheral diametersurface 16 of the tire bead assembly 12. FIG. 25 illustrates arubberless tire bead assembly 14 having a cushioning material or means44 positioned between the tire bead end 15 and the tire bead innerdiameter surface 16. The cushioning material may be rubber, reinforcedfabric material or even a metal, such as aluminum strip. FIG. 26illustrates a rubberless tire bead assembly 12 wherein the tire bead end15 is mechanically softened 45 by heat or flame treatment to soften theinner tire bead end 15 at the point where the end or ends engage thetire bead inner diameter surface 16 of the assembly 12. FIG. 27illustrates a rubberless tire bead assembly 12 in accordance with thepresent invention wherein the inner termination end or ends 15 of thewire element 14 includes a wedge means or member 46 positioned againstor adjacent to the termination end or ends 15 to reduce the stressconcentration between ends and the tire bead inner diameter surface 16of the tire bead assembly 12.

FIGS. 28 and 29 illustrate a multiple wire 14 3×3 rubberless tire beadassembly 12 which includes an elongated wrap material 48 having aportion 49 of the elongated wrap material anchored internal to the beadwire array and a portion 50 external to the bead assembly. Duringmanufacture of the 3×3 tire bead assembly 12, the portion 49 of theelongated wrap material internal to the bead assembly is anchored to aninterstice 52 between the wires at the final wrap ending of the 3×3 beadconstruction and the remaining portion 50, external to the beadconstruction, is continuously and spirally wrapped about the entire beadcircumference to retain the entire bead assembly in a planeperpendicular to the bead axis of revolution while having void volumes19 within the bead assembly. The elongated wrap material 48 may be abonding agent, such as a soldered coated steel wire or an extension ofthe wire element 14. The wrap material may also be a polymeric, glass,metal, or natural fiber material which is compatible with the cured tirecarcass when a bead assembly 12 is subsequently used in the tirebuilding process.

FIGS. 30a-30d schematically illustrate a forming method for themanufacture of a 2-3-2 rubberless tire bead assembly wherein theinternal inner diameter surface 16 of the tire bead assembly 12 is freeof the inner termination end 15 of the wire element 14. The bead former54 includes a rotatable cylindrical mandrel surface 56 and a radiallyexpandable rotatable mandrel 57. The bead former is rotated threerevolutions to position or deposit convolutions 1, 2 and 3 of the wireelement 14 into the former, the position as shown in FIG. 30a. After twomore revolutions of the former 54, convolutions 4 and 5 are deposited onthe former, as shown in FIG. 30b. At the beginning of the sixthrevolution of the former, the expandable mandrel 57 is radially movedoutwardly to position and move wire convolution 1 into the same level asconvolutions 4 and 5, as shown in FIG. 30c. After the seventh revolutionof the former, convolutions 6 and 7 are added to complete the 2-3-2rubberless tire bead assembly. Importantly, the termination ends 15 and17 are contained in convolution 1 and in convolution 7 and located inadjacent convolutions or positions, as shown in FIG. 30d. Thetermination ends 15 and 17 may be fastened one to the other by welding,brazing, soldering, gluing or ferruling. Thereafter, the formed tirebead assembly has applied to it the shape-retaining means as previouslydescribed to complete a bead assembly having an inner diameter surfacefree of any termination ends.

FIGS. 31a-31f schematically illustrate the method for forming a 2-3-2single wire rubberless tire bead assembly 12 from the a single wire 14wherein the resultant rubberless tire bead assembly has the tire beadinner diameter surface 16 free of any wire termination ends and whereinthe tire bead assembly 12 includes at least one wire termination endpositioned internally with respect to the tire bead assembly 12. Asshown in FIG. 31a, the expandable forming device 54 includes a V-shapedcavity 58 annularly and radially positioned to provide a segmentedcylindrical surface 56. The cavity 58 includes a first shoulder 59 and asecond shoulder 60 which cooperate with movable members 61 and 62, aswill hereinafter be described. As shown in FIG. 31a, the first wireconvolution 1 is positioned on the first shoulder 59 and the second wireconvolution 2 is positioned within the cavity 58, after two revolutionsof the forming device 54. After two additional revolutions of theforming device, wire convolutions 3 and 4 are deposited on thecylindrical mandrel surface 56 FIG. 31b and FIG. 31c shows thesimultaneous axial movement of the first movable member 61 to engagewire convolution 1 such that the surface of the wire 1 contacts wireconvolution 2. FIG. 31d shows that the wire convolution 5 is depositedon the second shoulder 60 and then wire convolution 6 is positionedabove wire convolution 4 after two additional revolutions of the former54. As shown in FIG. 31e, the final revolution of the former 54positions wire convolution 7 between wires 1 and 4. Thereafter, themovable member 62 is actuated and axially positions wires 5 and 6 in adense packed arrangement wherein the wire surfaces are touching withinterstitial void volumes between the convolutions of the wires tocomplete the 2-3-2 rubberless single wire tire bead assembly, as shownin FIG. 31f. In such a tire bead assembly, the outer end termination 17of the wire or convolution 7 is positioned internal with respect to thebody of the tire bead assembly 12 and the inner tire bead inner diametersurface 16 is free of any wire termination ends. Thereafter the formedtire bead assembly has applied to it the shape retaining means 20 tocomplete the bead assembly 12, as has been previously described.

FIGS. 32a-32f disclose a method of manufacturing a 2-3-2 rubberlesssingle wire tire bead assembly 12 from a single wire element wherein thewire termination ends 15 and 17 of the single wire are positionedinternal with respect to the body of the bead assembly and wherein thetire bead inner diameter surface 16 is free of any wire terminationends. The tire bead forming apparatus is similar to the apparatusdisclosed with respect to the method disclosed in FIGS. 31a-31f. Asshown in FIG. 32b, the wire convolution 1 is positioned on the firstshoulder 59 of the tire bead former 54 with the starting termination end15 bent inwardly at 15a, as shown from the top view in FIG. 32a. Afterthe first and second revolution of the former, wire convolution 1 ispositioned on the first shoulder 59 and wire convolution 2 is positionedwithin the V-shaped cavity 58, as shown in FIG. 32b and FIG. 32a. FIG.32d represents the depositing of wire convolutions 3 and 4 after twoadditional revolutions of the former and the simultaneous axial movementof convolution 1 by movable member 61 array such that the benttermination portion 15a positions termination end 15 in the center ofthe bead array.

After two additional revolutions of the former, wire convolutions 5 and6 are positioned, as shown in FIG. 32d. On the seventh revolution of theformer, wire convolution 7 is positioned within the tire bead array asshown in FIG. 32e. The inner termination end 15 of convolution 1 and theouter termination end 17 of convolution 7 are substantially in abuttingrelationship, as shown in dotted lines in FIG. 32e. The ends abut oneanother in a location which is internal to the bead assembly or arrayand wherein the resultant bead assembly has all surfaces free of anywire termination ends. If desired, after the formation of the beadassembly in such a manner, it may be desired to spot weld chemicallybond, mechanically join, etc., the end terminations 15 and 17 togetherto firmly retain the ends in abutting relationship to provide a unitaryrubberless tire bead assembly. Thereafter member 62 is axially moved toengage convolutions 5 and 6 to position the same about convolution 7, tothe position as shown in FIG. 32f and the top view in FIG. 32e. Afterthe tire bead assembly 12 has been formed, the various types ofshape-retaining means may be applied to the formed bead assembly toretain the bead assembly in a plane perpendicular to the bead axis ofrevolution for subsequent use in making a tire.

FIGS. 33a-33c schematically illustrate a method of forming andmanufacturing a six-wire, non-compact or non-dense tire bead assembly 12(FIG. 33c) having at least one wire termination end internal to the beadassembly and wherein each of the wires are held in symmetricalorientation by periodically placing profile shape-retaining means 20around the bead circumference to retain the completed tire bead assembly12 in a plane perpendicular to the bead axis of revolution. In makingthe six-wire, non-compact rubberless single wire tire bead assembly 12,as shown in FIG. 33c, the first four revolutions of the former 54 aremade sequentially in the same manner as the method disclosed in FIGS.31a-31c, wire convolution 1 is placed on intermediate flange 59, wrapnumber 2 is placed in the forming groove, as shown in FIG. 31a, wireconvolution 3 is positioned adjacent to wire convolution 2 within thegroove and then wire convolution 4 positioned outwardly of the groove,as shown in FIG. 31b. As convolution 4 is being completed, theintermediate flange and associated piston or cam positions wireconvolution 1 adjacent to wire convolution 2, the position as shown inFIG. 31c. The movable member 62 is to permit the alignment of wireconvolution 5 substantially over wire convolution 4, the position asshown in FIG. 33a. Thereafter, the final revolution of the former 54deposits wire convolution 6 internally of the tire bead assembly 12.When convolution 6 is completed, the member 62 is axially moved toposition and move wire convolution 5 substantially centering the sameupon wire convolution 6 to complete tire bead assembly, as shown in thedotted line in FIG. 33b. At this point in the assembly, the wireconvolution 1 would have a termination end externally on the sidewall ofthe tire bead assembly and the outer termination end of wire convolution6 would be positioned internally within the bead assembly. After thesix-wire, rubberless, non-compact tire bead assembly has been so formed,profiled shape-retaining means 20 are positioned around the beadcircumference to retain the bead assembly 12 in a planar configuration,as shown in FIG. 33c. The profiled shape-retainer means or member 20provides that the elongated wire element axis 1-6 are retained parallelrelative to one another and in parallel from convolution to convolutionwith the elongated element surfaces in direct contact with each othersuch that void volumes 19 exist between the wire elements to completethe six-wire, non-compact, rubberless single wire tire bead assembly 12.Other previously described shape-retaining means are also envisioned asare constructions other than those given as examples.

FIGS. 34a-34e schematically illustrate the method of forming arubberless 4×4 tire bead assembly 12 utilizing multiple wires 14, withthe tire bead assembly having a tapered bead base 13 or a tapered tirebead inner diameter surface 16. The tire bead former 54 includes atapered radially extending cylindrical surface 56 and radiallyexpandable mandrel 57 which define a tapered cavity 58 therebetween.Rotation of the former permits the placement of four wires 14a-14dsimultaneously onto the surface 56 to provide the first row or layer ofthe single convolutions of the respective four wires 14a-14d into thetapered cavity 58, the position as shown in FIG. 34a. FIG. 34billustrates the revolution of the former wherein the four wires 14a-14dprovide an overlapping second row or layer of wires. As illustrated inFIG. 34c, the third wrapping of the respective four wires 14a-14d uponthemselves provides a third row or layer of the tire bead assembly. Thefinal and fourth row of the respective four wires 14a-14d is wrappedupon themselves to complete the multiple wire tire bead assembly 12having a tapered base or inner diameter surface 16, as shown in FIG.34d. After the final convolutions of the respective multiple wires arepositioned and wrapped on the former, shape-retaining means 20, asdescribed above, engage the tire bead assembly 12, to provide thecompleted multiple wire 4×4 tapered base tire bead assembly 12, as shownin cross-section in FIG. 34e. Such a multiple wire tapered baseconstruction is novel because it is not possible to make a tapered basetire assembly wherein multiple wires are contained in a rubber ribbon oftape material as known and disclosed in the prior art and explainedpreviously. The unique tire bead assembly 12 of the present inventionprovides a dense packed, 4×4 construction, wherein the tapered innerdiameter 16 of the bead assembly will include tire bead innertermination ends 15 on the inside surface thereof, which may be treatedby mechanical deformation, heat softening treatment or the utilizationof cushioning means between the inner termination ends and the tire beadinner diameter surface 16, as disclosed in FIGS. 22, 24-27, to improvethe strength efficiencies of such rubberless tire bead assemblies.

One method of making a tire bead assembly comprised of a plurality ofwires is illustrated in FIGS. 35a-35c. The tire bead former 54 isidentical to the former disclosed in FIGS. 34a-34e, except it includes acylindrical mandrel surface 56, as previously disclosed. The 4×4multiple wire tire bead assembly 12 is manufactured by rotating theformer one revolution and simultaneously feeding four wire elements14a-14d onto the cylindrical surface 56, as shown in FIG. 35a. FIG. 35brepresents the feeding of two convolutions of the four wire elements14a-14d onto surface 56 and FIG. 35c illustrates the feeding of fourconvolution of the four wire elements onto the surface 56. Thereafter,the rubberless tire bead assembly 12 will be engaged with theshape-retaining means 20 to complete the multiple wire 4×4 rubberlesstire bead assembly. Because the assembly will have four termination ends15 on the inner diameter surface 16 of the tire bead, the ends 15 may bemechanically deformed, heat treated or cushioning means positionedbetween the ends 15 and the inner surface of the tire bead assembly, ashas been disclosed in FIGS. 22 and 24-27.

Furthermore, it should be apparent that multiple wire bead assembliessuch as the 4×4 construction described above and in FIG. 35c may bereadily produced with the resultant tire bead assembly having at leastsome of the wire end terminations internal to the wire array byutilizing forming drums having movable elements and temporary wireposition locating shoulders similar to those described in FIGS. 30, 31,32, and 33 for single wire bead assemblies. As is apparent, the tireassembly would have the inner diameter surface free of end terminations,with some of the end terminations positioned internal to the completedtire bead assembly.

FIGS. 36a-36c illustrate another method of making a 4×4 rubberless tirebead assembly 12 containing multiple wires 14a-14d in accordance withthe present invention. As shown in FIG. 36a, one revolution of theformer 54 permits multiple wires 14a, 14b, 14c, and 14d to besimultaneously wrapped around the cylindrical surface 56 to provide afirst layer extending radially outwardly. FIG. 36b represents theaddition of a second layer, wires 14a-14b, axially positioned on theformer 54, and FIG. 36c represents the addition of the fourth layer,14a-14d, to complete the 4×4 multiple wire, rubberless tire beadassembly 12. As shown in FIG. 36c and in FIG. 37, the outer terminationends 17 of the wire elements 14a-14d are positioned on the sidewall 27of 4×4 rubberless tire bead assembly 12 and the inner tire bead innerdiameter surface 16 is free of any termination ends. Such a tire beadassembly is not possible utilizing the ribbon-type, rubber-coated wireelements in accordance with the prior art because the prior artstrengthening elements do not permit the simultaneous feeding of each ofthe respective wires in both a radial and an axial direction, a resultwhich can be achieved utilizing the present invention. It should beapparent that a multitude of constructions other than the 4×4construction of this example are possible.

Additionally, the novel rubberless tire bead construction utilizingmultiple bead wires in accordance with the present invention providesthat in each convolution of the wire element, or elements, the surfacesof each wire are in contact with each other over substantially theentire circumference of the bead assembly while providing for voidvolumes 19 within the completed tire bead assembly. After completion ofthe assembly as shown in FIG. 36c, shape-retaining means are positionedperiodically about the bead circumference to retain the completedmultiple wire 4×4 wire bead assembly 12 in a planar configuration forsubsequent use in manufacturing a tire.

It is also within the scope of the present invention that the method ofsimultaneously depositing a plurality of multiple wires axially toprovide a multiple wire tire bead assembly may be used in manufacturingthe tapered base 4×4 tire bead assembly, as shown in FIGS. 34a-34d. Insuch an instance, the end terminations of the last wrap would be on thesidewall of the tapered 4×4 tire bead assembly and the resultantassembly would not possess any termination ends positioned on thetapered inner diameter surface 16, as is present in the tapered 4×4 tirebead assembly of FIGS. 34a-34d.

The strength efficiency of tire bead assemblies in accordance with thepresent invention has resulted in tire bead assemblies possessingstrength efficiencies substantially equivalent to conventional roundwire beads having a rubber bonding or coating on the wires.

The practical advantages of eliminating the rubber coating from the tirebead assembly includes eliminating the cost of the bead rubber coatingand results in improved manufacturing operations such as higher cyclespeeds, increased productivity during the bead making operation, andelimination of concern about the shelf life, or aging, of beads.

The methods of simultaneously feeding multiple wires free of any rubbercoating thereon permits the manufacture of symmetrical and denselypacked tire bead assemblies which have tapered inner diameter tire beadsurfaces. The manufacturing of rubberless tire bead assemblies havingthe substantially equivalent to conventional round wire beads having arubber bonding or coating on the wires.

The practical advantages of eliminating the rubber coating from the tirebead assembly includes eliminating the cost of the bead rubber coatingand results in improved manufacturing operations such as higher cyclespeeds, increased productivity during the bead making operation, andelimination of concern about the shelf life, or aging, of beads.

The methods of simultaneously feeding multiple wires free of any rubbercoating thereon permits the manufacture of symmetrical and denselypacked tire bead assemblies which have tapered inner diameter tire beadsurfaces. The manufacturing of rubberless tire bead assemblies havingthe wire termination ends positioned internal to the tire bead assemblyor on the sidewall of the tire bead assembly has heretofore beenunknown. The uniformity of weight distribution around the rubberlesstire bead assembly having wire termination ends positioned internallyshould be much improved over state-of-the-art beads containing rubbercoatings and overlap regions.

Referring to FIG. 38, it is shown a simplified representation of anapparatus 70 provided in accordance with one embodiment of the presentinvention for forming a rubberless bead assembly 12. The apparatus 70includes a bead former 71, a drive assembly represented by shaft 72 forthe bead former 71 and an applicator device 73. The bead former 71 has arotatable forming surface 74 (best shown in FIG. 40) for receiving froma source of wire (not shown) multiple convolutions of a single wire 14which is substantially free of elastomeric material.

The drive assembly 72 rotates the forming surface 74 of the bead former71 to produce a bead hoop or assembly 12 comprised of a plurality ofconvolutions of the single wire 14.

After the bead hoop or assembly has been formed on the former 71, theapplicator device 73 applies a shape retaining component or element 20(FIG. 39) to the formed bead hoop or assembly 12 to retain the bead hoopin a planar configuration perpendicular to the axis of the revolution ofthe bead hoop and to retain each convolution of the single wire insubstantially wire-to-wire contact with at least one adjacentconvolution of the single wire 14.

The shape retaining component, element or means 20 may take variousforms as has been described above and by way of example a finished tirebead hoop or assembly 12 illustrated in FIG. 39 includes three bands 20.The shape retaining component or element may comprise a variety ofwrapping materials such as tapes, films, wires or the like. Also, theshape retaining component or element 20 may be any of theshape-retaining means, as described hereinabove in FIGS. 5-29.

In applying the shape-retaining component or element to the formed beadhoop, the applicator device 73 is movable relative to the bead former 71as represented by the arrow 79 in FIG. 38.

The bead former 71 defines the bead forming surface 74 and preferablyincludes two members 81 and 82 which are separable from one another tofacilitate removal of the formed bead from the former, as shown in FIGS.38 and 40. Now, referring to FIG. 40, in accordance with a furtheraspect of the invention, the apparatus 70 for forming a rubberless beadassembly 12 includes a moving apparatus represented by a disc-shapedmember 85 which moves the formed bead hoop from the bead formingposition, indicated generally at 88, to a second position indicatedgenerally at 89 where the applicator apparatus 73 (shown in FIG. 38)applies the shape-retaining component or element 20 to the formed beadhoop.

The first member 81 is rotatably mounted on the moving member 85. Thesecond member 82 is adapted to be coupled to the first member 81 andcoupled to the drive means (not shown) by way of the drive shaft 72. Thefirst and second members 81 and 82 define the bead forming surface 74.

In forming the bead hoop, the bead former 71 is driven by the driveassembly to receive multiple convolutions of a single wire 14 from thewire source. When the bead hoop has been formed, the second member 82 isretracted axially, as shown by arrow 90, and decoupled from the firstmember 81. The moving assembly 85 is then rotated to move the member 81with the formed bead hoop thereon to the second position 89, whilemoving the complementary member 81 to the bead forming position 88 foruse in the forming of a further bead hoop. When the first member 81 withthe formed bead hoop thereon is located at the second position 89, theapplication device 73 is operatively engaged with the formed bead hoopto apply the shape-retaining component or element 20 thereto to completethe formation of the tire bead assembly 12. Thereafter the assembly 12is removed from member 81.

Referring to FIG. 41, in accordance with a further embodiment for theapparatus for forming a rubberless tire bead assembly 12, a movingapparatus 91 comprises a plurality of gripping elements 92 carried by asuitable control mechanism 94 and in turn positionable by way of a shaft96 to engage a formed bead hoop which has been formed on a formingsurface 74 on a bead former 71. The gripping elements 92 engage theformed bead hoop at at least at two locations about the bead hoopcircumference to remove the bead hoop from the bead former and to locatethe bead hoop at a further position where an applicator device 73 (shownin FIG. 38) applies the shape-retaining means 20 to the formed beadhoop. The gripping elements which engage the formed bead hoop maintainthe formed bead hoop in a planar configuration perpendicular to the axisof rotation of the bead hoop during movement of the bead hoop from thebead forming position to the second position where the applicator meansapplies shape-retaining components or elements to the bead hoop.

The control device 94 may include means (not shown) for progressivelyreleasing the gripping elements 92 from the bead hoop circumference insequence during progressive application of the shape-retaining componentor element 20 (as shown in FIG. 23) when such shape-retaining componentor element is an elongated material spirally wrapped about the beadhoop.

I claim:
 1. An apparatus for forming a rubberless tire bead assembly,said apparatus comprising:a bead former having a forming surfacerotatable about a fixed axis of revolution, said forming surface adaptedfor receiving multiple substantially parallel convolutions of apredetermined length of a single wire substantially free of elastomericmaterial from a wire source, rotating means for rotating said formingsurface on said bead former within a single plane normal to said fixedaxis of revolution to produce a bead hoop comprised of a plurality ofsubstantially parallel convolutions of said predetermined length of asingle wire in a planar configuration with each convolution of thesingle wire in substantially parallel orientation and in wire-to-wirecontact with at least one adjacent convolution of said single wire, andan applicator means for applying shape retaining means to said formedbead hoop on said bead former at a plurality of circumferential spacedpositions about the circumference of the bead hoop to retain the beadhoop in a planar configuration perpendicular to the axis of revolutionof the bead hoop, with said bead former including means adaptable forreceiving said applicator means for applying said shape retaining meansto said formed bead hoop to retain each convolution of the single wirein substantially parallel orientation and in wire-to-wire contact withat least one adjacent convolution of said single wire along the entirecircumference of each respective convolution.
 2. The apparatus inaccordance with claim 1 wherein said apparatus includes moving means formoving said bead former with said formed bead hoop thereon from a beadforming position to a second position for cooperation with saidapplicator means for applying said shape retaining means to the saidformed bead hoop on said bead former.
 3. The apparatus in accordancewith claim 2 wherein said moving means is rotatable about an axis tomove said bead former and said formed bead hoop thereon from the beadforming position to said second position.
 4. The apparatus in accordancewith claim 3 wherein said bead former is comprised of at least first andsecond members, with said first member being coupled to said rotatingmeans and defining at least a portion of said forming surface and saidsecond member being adapted for engagement with said first member duringthe bead forming operation, with one of said members being movablewithin said single plane normal to the fixed axis of revolution of saidbead former to said second position to facilitate application of shaperetaining means and removal of said formed bead.
 5. The apparatus inaccordance with claim 4 wherein one of said members is movable axiallywith respect to the other member.
 6. The apparatus in accordance withclaim 5 wherein said second member is mounted on said moving means androtatable relative to said moving means during the bead formingoperation when engaged with said first member.
 7. The apparatus inaccordance with claim 1 wherein said bead former is comprised of firstand second members, with said first member being coupled to saidrotating means and defining at least a portion of said forming surfaceand said second member being adapted for axial movement and engagementwith said first member during the bead forming operation, with one ofsaid members being axially movable with respect to the other member tofacilitate removal of said formed bead.
 8. An apparatus for forming arubberless tire bead assembly, said apparatus comprising:a bead formerhaving a forming surface rotatable about a fixed axis of revolution,said forming surface adapted for receiving multiple substantiallyparallel convolutions of a predetermined length of a single wiresubstantially free of elastomeric material from a wire source, rotatingmeans for rotating said forming surface on said bead former within asingle plane normal to said fixed axis of revolution to produce a beadhoop comprised of a plurality of substantially parallel convolutions ofsaid predetermined length of a single wire in a planar configurationwith each convolution of the single wire in substantially parallelorientation and in wire-to-wire contact with at least one adjacentconvolution of said single wire, and means for removing said formed beadhoop from said bead former to a second position, and an applicator meansassociated with said second position for applying shape retaining meansto said formed bead hoop at a plurality of circumferential spacedpositions about the circumference of the bead hoop to retain the beadhoop in a planar configuration perpendicular to the axis of revolutionof the bead hoop, with said second position including means adaptablefor receiving said applicator means for applying said shape retainingmeans to said formed bead hoop to retain each convolution of the singlewire in substantially parallel orientation and in wire-to-wire contactalong the entire circumference of each respective convolution.
 9. Theapparatus in accordance with claim 8 wherein said means for removing iscomprised of gripping elements which engage the formed bead hoop at atleast two locations about the bead hoop circumference to remove the beadhoop from the bead former and to locate the bead hoop at the secondposition.
 10. The apparatus in accordance with claim 9 wherein saidgripping elements maintain said formed bead hoop in a planarconfiguration perpendicular to the axis of rotation of the bead hoopduring movement of the bead hoop from the bead former to the secondposition.
 11. The apparatus in accordance with claim 11 wherein saidshape retaining means is comprised of an elongated material spirallywrapped about the bead hoop.
 12. An apparatus for forming a rubberlesstire bead assembly, said apparatus comprising:a bead former having aforming surface rotatable about a fixed axis of revolution, said formingsurface adapted for receiving multiple wraps of multiple substantiallyparallel wire of a predetermined length substantially free ofelastomeric material from a wire source, rotating means for rotatingsaid forming surface on said bead former within a single plane normal tosaid fixed axis of revolution to produce a bead hoop comprised of aplurality of substantially parallel convolutions of said multiple wireof predetermined length in a planar configuration with adjacentconvolutions of said multiple wires in substantially parallelorientation and in wire-to-wire contact, and an applicator means forapplying shape retaining means to said formed bead hoop on said beadformer, at a plurality of circumferential spaced positions about thecircumference of the bead hoop to retain the bead hoop in a planarconfiguration perpendicular to the axis of revolution of the bead hoopwith said bead former including means adaptable for receiving saidapplicator means for applying said shape retaining means to said formedbead hoop to retain adjacent convolutions of said multiple wires insubstantially parallel orientation and in wire-to-wire contact along theentire circumference of each respective convolution.
 13. The apparatusin accordance with claim 12 wherein said apparatus includes moving meansfor moving said bead former with said formed bead hoop thereon from abead forming position to a second position for cooperation with saidapplicator means for applying said shape retaining means to the saidformed bead hoop on said bead former.
 14. The apparatus in accordancewith claim 13 wherein said moving means is rotatable about an axis tomove said bead former and said formed bead hoop thereon from the beadforming position to said second position.
 15. The apparatus inaccordance with claim 14 wherein said bead former is comprised of atleast first and second members, with said first member being coupled tosaid rotating means and defining at least a portion of said formingsurface and said second member being adapted for engagement with saidfirst member during the bead forming operation, with one of said membersbeing movable within said single plane normal to the fixed axis ofrevolution of said bead former to said second position to facilitateapplication of shape retaining means and removal of said formed bead.16. The apparatus in accordance with claim 15 wherein one of saidmembers is movable axially with respect to the other member.
 17. Theapparatus in accordance with claim 16 wherein said second member ismounted on said moving means and rotatable relative to said moving meansduring the bead forming operation when engaged with said first member.18. The apparatus in accordance with claim 12 wherein said bead formeris comprised of first and second members, with said first member beingcoupled to said rotating means and defining at least a portion of saidforming surface and said second member being adapted for axial movementand engagement with said first member during the bead forming operation,with one of said members being axially movable with respect to the othermember to facilitate removal of said formed bead.
 19. An apparatus forforming a rubberless tire bead assembly, said apparatus comprising:abead former having a forming surface rotatable about a fixed axis ofrevolution, said forming surface adapted for receiving multiple wraps ofmultiple substantially parallel wires of a predetermined lengthsubstantially free of elastomeric material from a wire source, rotatingmeans for rotating said forming surface on said bead former within asingle plane normal to said fixed axis of revolution to produce a beadhoop comprised of a plurality of substantially parallel convolutions ofsaid multiple wires of predetermined length in a planar configurationwith adjacent convolutions of said multiple wires in substantiallyparallel orientation and in wire-to-wire contact, means for removingsaid formed bead hoop from said bead former to a second position, anapplicator means associated with said second position for applying shaperetaining means to said formed bead hoop, at a plurality ofcircumferential spaced positions about the circumference of the beadhoop to retain the bead hoop in a planar configuration perpendicular tothe axis of revolution of the bead hoop, with said second positionincluding means adaptable for receiving said applicator means forapplying said shape retaining means to said formed bead hoop to retainadjacent convolutions of said multiple wires in substantially parallelorientation and in wire-to-wire contact along the entire circumferenceof each respective convolution.
 20. The apparatus in accordance withclaim 19 wherein said means for removing is comprised of grippingelements which engage the formed bead hoop at at least two locationsabout the bead hoop circumference to remove the bead hoop from the beadformer and to locate the bead hoop at the second position.
 21. Theapparatus in accordance with claim 20 wherein said gripping elementsmaintain said formed bead hoop in a planar configuration perpendicularto the axis of rotation of the bead hoop during movement of the beadhoop from the first to the second position.
 22. The apparatus inaccordance with claim 19 wherein said shape retaining means is comprisedof an elongated material spirally wrapped about the bead hoop.
 23. Anapparatus for forming a rubberless tire bead assembly, said apparatuscomprising:a bead former having a forming surface rotatable about anaxis of revolution, said forming surface being adapted for receivingmultiple convolutions of a single wire substantially free of elastomericmaterial from a wire source, rotating means for rotating said formingsurface on said bead former within a single plane normal to said axis ofrevolution to produce a bead hoop comprised of a plurality ofconvolutions of said single wire, applicator means for applying shaperetaining means to the formed bead hoop to retain the bead hoop in aplanar configuration perpendicular to the axis of revolution of the beadhoop and to retain each convolution of the single wire in substantiallywire-to-wire contact with at least one adjacent convolution of saidsingle wire, and moving means rotatable about an axis to move said beadformer with said formed bead hoop thereon from a bead forming positionto a second position for cooperation with said applicator means forapplying said shape retaining means to said formed bead hoop on saidbead former, said bead former being comprises of at least first, secondand third members, said first member being coupled to said rotatingmeans and defining at least a portion of said forming surface, saidsecond member being mounted on said moving means and adapted forengagement with said first member at said bead forming position during abead forming operation, and after a bead hoop has been formed, saidsecond member being moved by said moving means within said single planeto said second position to facilitate removal of the formed bead hoop,and said third member being mounted on said moving means and beingmovable within said single plane, said third member being moved by saidmoving means between said position and said bead forming position whilesaid second member is being moved from said bead forming position tosaid second position, and said third member being adapted for engagementwith said first member at said bead forming position during a subsequentbead forming operation.
 24. An apparatus for forming a rubberless tirebead assembly, said apparatus comprising:a bead former having a formingsurface rotatable about an axis of revolution, said forming surfaceadapted for receiving multiple wraps of multiple wires substantiallyfree of elastomeric material from a wire source, rotating means forrotating said forming surface on said bead former within a single planenormal to said axis of revolution to produce a bead hoop comprised of aplurality of convolutions of said multiple wires, an applicator meansfor applying shape retaining means to said formed bead hoop on said beadformer to retain the bead hoop in a planar configuration perpendicularto the axis of revolution of the bead hoop and to retain adjacentconvolutions of said multiple wires in substantially wire-to-wirecontact, and moving means rotatable about an axis to move said beadformer with said formed bead hoop thereon from a bead forming positionto a second position for cooperation with said applicator means forapplying said shape retaining means to said formed bead hoop on saidbead former, said bead former being comprised of at least first, secondand third members, said first member being coupled to said rotatingmeans and defining at least a portion of said forming surface, saidsecond member being mounted on said moving means and adapted forengagement with said first member at said bead forming position during abead forming operation, and after a bead hoop has been formed, saidsecond member being moved by said moving means within said single planeto said second position to facilitate removal of the formed bead hoop,said third member being mounted on said moving means and being movablewithin said single plane, said third member being moved by said movingmeans between said second position and said bead forming position whilesaid second member is being moved from said bead forming position tosaid second position, and said third member being adapted for engagementwith said first member at said bead forming position during a subsequentbead forming operation.
 25. An apparatus for forming a rubberless tirebead assembly, said apparatus comprising:a bead former having a formingsurface rotatable about a fixed axis of revolution, said forming surfaceadapted for receiving multiple substantially parallel convolutions of apredetermined length of a single wire substantially free of elastomericmaterial from a wire source, rotating means for rotating said formingsurface on said bead former within a single plane normal to said fixedaxis of revolution to produce a bead hoop comprised of a plurality ofsubstantially parallel convolutions of said predetermined length of asingle wire in a planar configuration with each convolution of thesingle wire in substantially parallel orientation and in wire-to-wirecontact with at least one adjacent convolution of said single wire, afirst applicator means for applying precursor shape retaining means tosaid formed bead hoop on said bead former at a plurality ofcircumferential spaced positions about the circumference of the beadhoop to retain the bead hoop in a planar configuration perpendicular tothe axis of revolution of the bead hoop, with said bead former includingmeans adaptable for receiving said applicator means for applying saidprecursor shape retaining means to said formed bead hoop to retain eachconvolution of the single wire in substantially parallel orientation andin wire-to-wire contact with at least one adjacent convolution of saidsingle wire, and means for moving said bead former and said formed beadhoop thereon to a second position for cooperation with a secondapplicator means for applying shape retaining means to said formed beadhoop to retain adjacent convolutions in parallel orientation and inwire-to-wire contact along the entire circumference of each respectiveconvolution.
 26. An apparatus for forming a rubberless tire beadassembly, said apparatus comprising:a bead former having a formingsurface rotatable about a fixed axis of revolution, said forming surfaceadapted for receiving multiple wraps of multiple substantially parallelwires of a predetermined length substantially free of elastomericmaterial from a wire source, rotating means for rotating said formingsurface on said bead former within a single plane normal to said fixedaxis of revolution to produce a bead hoop comprised of a plurality ofsubstantially parallel convolutions of said multiple wires ofpredetermined length in a planar configuration with adjacentconvolutions of said multiple wires in substantially parallelorientation and in wire-to-wire contact, a first applicator means forapplying precursor shape retaining means to said formed bead hoop onsaid bead former, at a plurality of circumferential spaced positionsabout the circumference of the bead hoop to retain the bead hoop in aplanar configuration perpendicular to the axis of revolution of the beadhoop with said bead former including means adaptable for receiving saidapplicator means for applying said shape retaining means to said formedbead hoop to retain adjacent convolutions of said multiple wires insubstantially parallel orientation and in wire-to-wire contact, andmeans for moving said bead former and said formed bead hoop thereon to asecond position for cooperation with said applicator means for applyingsaid shape retaining means to said formed bead hoop to retain adjacentconvolutions in parallel orientation and in wire-to-wire contact alongthe entire circumference of each respective convolution.